Modular push switch mechanism

ABSTRACT

The present invention is directed to switch device that includes a switch actuator having a user-accessible surface, the user accessible surface including an indicator element and an interior channel optically coupled to the indicator element. The switch actuator is configured to actuate a mechanical linkage by moving between a first actuator position and a second actuator position in response to a user-stimulus, the mechanical linkage actuation driving the set of electrical contacts between a first contact state and a second contact state. A light emitting portion is disposed within the interior channel and optically coupled to the indicator element so that the interior channel moves relative to the light emitting portion when the switch actuator moves between the first actuator position and the second actuator position. The light emitting portion is optically coupled to the indicator element when the interior channel moves relative to the lighting portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is application is a continuation of U.S. patent application Ser.No. 13/782,195, filed on Mar. 1, 2013, which is a continuation-in-partof U.S. patent application Ser. No. 13/680,675 filed on Nov. 19, 2012,the contents of which are relied upon and incorporated herein byreference in its entirety, and the benefit of priority under 35 U.S.C.§120 is hereby claimed, U.S. patent application Ser. No. 13/680,675claims priority under to U.S. Provisional Patent Application No.61/635,432, the content of which is relied upon and incorporated hereinby reference in its entirety, and the benefit of priority under 35U.S.C. §119(e) is hereby claimed.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to electric switches, andparticularly to electric switches that include mechanical actuators.

2. Technical Background

Electrical switches are used, of course, to control the state ofelectrical loads such as lighting elements, fans, and other suchequipments. Electrical switch units are typically wall mounted in alocation that is proximate the load. For example, light switches areusually located at the entry point of a room or a space so that a personentering the room can turn the lights ON before entering. Wall mountedelectrical switches often include mechanical actuators such as toggleswitch actuators, lever switch actuators, paddle switch actuators,push-button actuators and the like.

Based on consumer taste and convenience, there is a need for a pushbutton actuated electrical switch. The push button switches currently onthe market almost always include electronic switch actuators because ofthe in-out motion of a push switch lends itself to electronicpush-button switch actuators rather than mechanical switch actuators.However, electronic switch actuators have drawbacks relative tomechanical switch actuators. They are more expensive, generate morethermal energy (heat), are larger, and are not as robust. What isneeded, therefore, is a push button switch that includes a mechanicalactuator to mitigate the aforementioned drawbacks.

In one approach that has been considered, a push button actuator iscoupled to a rotatable block by a pressure-transmission gear. Thisapproach has several drawbacks associated with it. Thepressure-transmission gear is laterally unstable and the interfacebetween the pressure-transmission gear and the rotatable block is proneto being jammed when the user applies downward pressure to the pushbutton actuator. Another drawback to this approach relates to thetendency for contaminants to enter the mechanical switch space andfouling the switch contacts. What is needed, therefore, is a push buttonswitch that includes a mechanical actuator that overcomes theaforementioned drawbacks.

Another issue that arises in various types of switching devices relatesto the function and placement of indicator lights on the switchingdevice itself. Some switches are known to include a pilot light that isilluminated when the switch is turned OFF. A load light is one that isilluminated when the switch is turned ON; this type of light providesthe user with an indication that power is being delivered to the load.Another type of indicator is a “power-available light.” This indicatorshows the user that power is available to the switch, and thus, isilluminated—when power is available—regardless of whether the switch isON or OFF. One drawback associated with mechanical switch devices (thatinclude indicator lights) relates to the fact that the switch actuatoris movable. If the light indicator element within the switch moves withthe switch actuator, then the light output is substantially uniform. Onthe other hand, the electrical wiring must move with the light element(to provide electricity); as a result, the wiring is continually beingflexed. If, on the other hand, the light indicator element within theswitch is stationary, the continual flexure of the electrical wiring isavoided while providing the mechanical switch actuator freedom ofmotion. The drawback with this solution is that the light output of astationary light will be non-uniform. For one type of indicator light oranother, the light output will be more effective in one actuatorposition than another. This issue becomes especially apparent for thepower-available light or for universal light assemblies that can bewired by the installer to accomplish the various functions. What isneeded, therefore, is an indicator arrangement (within the switch) thatprovides efficient and consistent light output regardless of actuatorposition.

Turning now to another consideration, there are several drawbacksassociated with conventional installation methods and conventionalprotective electrical wiring devices. Conventional protective electricalwiring devices often do not make efficient use of space. In addition,mounting the wiring device's ground strap to the device box is tedious,time consuming, and therefore costly. The same can be said of mountingthe cover plate to the electrical wiring device. Moreover, in multi-ganginstallations, the finished look is often ragged because the pluralityof electrical devices and their respective cover plates are typicallynot in alignment. This misalignment can be, and very often is, in allthree dimensions. Retrofitting an electrical installation can also beproblematic from the standpoint of the finished look because the devicebox, or an old work box, may not be precisely aligned to the plane ofthe wall surface. This is especially true if the wall surface itself isuneven. After remodeling a space, homeowners often seek to replace anexisting wall plate with one that better matches the new decor. Thus, ahomeowner may inadvisably remove the faceplate cover from an energizedwiring device and inadvertently become exposed to a shock hazard fromthe “hot” electrical wiring.

What is needed therefore is a switch that addresses the drawbacksarticulated above. A switch of this type is also needed that can beemployed in a number of different form factors including one suitablefor use in a modular framing system such that it does not requirefasteners to be securely installed within the device box.

SUMMARY OF THE INVENTION

The present invention addresses the needs described above by providing apush-switch with a mechanical switch actuator that addresses thedrawbacks articulated above. The switch of the present invention can beemployed in a number of different form factors including a form factorsuitable for use in a modular framing system.

One aspect of the present invention is directed to a switch thatincludes a device housing configured to be installed in an outlet box,the device housing including front portion and a back body portion. Aswitch assembly is disposed in the device housing, the switch assemblyincluding a switch actuator having a user-accessible surface and coupledto the front portion. The user accessible surface includes an indicatorelement disposed therein. The switch actuator also includes an interiorchannel optically coupled to the indicator element. The switch assemblyfurther includes a mechanical linkage and a set of electrical contactsdisposed within the back body portion. The switch actuator is configuredto actuate the mechanical linkage by moving between a first actuatorposition and a second actuator position in response to a user-stimulus,the mechanical linkage actuation driving the set of electrical contactsbetween a first contact state and a second contact state. A lightingassembly is coupled to the back body portion at a fixed position so thata light emitting portion of the lighting assembly is disposed within theinterior channel and optically coupled to the indicator element. Theinterior channel is configured to move relative to the light emittingportion when the switch actuator moves between the first actuatorposition and the second actuator position. The light emitting portion isoptically coupled to the indicator element when the interior channelmoves relative to the lighting portion.

In one embodiment, the lighting assembly is a modular componentremovably coupled to the back body portion.

In one embodiment, the back body portion includes an elongated chamberconfigured to accommodate the lighting assembly, the elongated chamberincluding a tapered portion configured to position the light emittingportion at the fixed position.

In one embodiment, the switch actuator includes a light transmittingelement configured to optically couple the interior channel to theindicator element.

In one version of the embodiment, the light transmitting element is in afixed positional relationship with the interior channel.

In one version of the embodiment, the light transmitting elementincludes an LED element.

In one embodiment, the switch actuator includes a light transmittingelement having a first optical port and a second optical port, the firstport being coupled to the indicator element and the second port beingcoupled to the interior channel, and wherein the first optical port issubstantially aligned with a central axis of the device housing and thesecond optical port is substantially offset from the axis.

In one version of the embodiment, the light transmitting elementincludes a plurality of light transmitting segments disposed between thefirst port and the second ports.

In one version of the embodiment, the plurality of light transmittingsegments includes at least one portion configured to direct incidentlight at a 45° angle.

In one embodiment, the interior channel is polished.

In one embodiment, the interior channel is plated with an opticallyreflective material.

In one embodiment, the set of electrical contacts are switchably coupledto a plurality of terminals at least partially disposed in the back bodyportion, the plurality of terminals being accessible via the back bodyportion.

In one version of the embodiment, the plurality of terminals including aline terminal, a load terminal or a traveler terminal.

In one embodiment, the indicator element is a lens element.

In one version of the embodiment, the lens element is formed bymachining a portion of the user accessible surface.

Another aspect of the invention is directed to a switch device thatincludes a switch actuator assembly having a switch actuation platecoupled to an actuator guide portion that has a perimeter guide wallsubstantially enclosing an interior volume therewithin. The actuatorguide portion is coupled to a force transmission member and furtherincludes an interior channel. The switch actuation plate includes a lenselement optically coupled to a light transmission structure at leastpartially disposed in the interior channel. A back body member includesa perimeter back body wall, portions of the perimeter back body wallbeing configured to mate with corresponding portions of the perimeterguide wall so that the perimeter guide wall is disposed within theperimeter back body wall in a nesting arrangement so that the interiorvolume is substantially inaccessible to an exterior region of thedevice. The back body member includes an elongated chamber configured toposition a lighting element at a fixed position within the back body sothat the lighting element extends into the interior channel. Theactuator guide is configured to slide within the back body member in asubstantially linear motion between a non-switch actuating position anda switch actuating position so that a relative distance between thelight transmission structure and the lighting element varies within theinterior channel. The interior channel is configured so that lightintensity emitted by the lighting element via the lens element issubstantially constant while the relative distance varies. A mechanicalswitch assembly configured to convert the linear motion of the actuatorguide into a rotational movement when the switch actuator plate isdepressed so that the mechanical switch mechanism moves between a firstswitch state and a second switch state.

In one embodiment, the interior channel is polished.

In one embodiment, the interior channel is plated with an opticallyreflective material.

In one embodiment, the light transmitting element includes a firstoptical port and a second optical port, the first port being coupled tothe lens element and the second port being coupled to the interiorchannel, and wherein the first optical port is substantially alignedwith a central axis of the device housing and the second optical port issubstantially offset from the axis.

In one version of the embodiment, the light transmitting elementincludes a plurality of light transmitting segments disposed between thefirst port and the second ports.

In one version of the embodiment, the plurality of light transmittingsegments includes at least one portion configured to direct incidentlight at a 45° angle.

In one embodiment, the actuator guide portion includes a plurality ofguide portions formed in the perimeter wall within the interior volume,the perimeter back body wall having a plurality of registrationelements, each of the plurality of registration elements beinginsertably disposed within a corresponding one of the plurality of guideportions.

In one version of the embodiment, the plurality of registration elementsare configured to substantially prevent rotational movement of theactuator guide within the back body member about an axis of the switchdevice normal to the direction of linear movement.

In one version of the embodiment, the plurality of registration elementsare configured to substantially prevent rotational movement of theactuator guide within the back body member about the central axis.

In one version of the embodiment, the guide elements includes a firstguide channel and a second guide channel formed on a first perimeterguide wall and a second perimeter guide wall, respectively, and a firstguide post and a second guide post formed on a third perimeter guidewall and a fourth perimeter guide wall, respectively.

In one version of the embodiment, the plurality of registration elementsincludes a first registration column and a second registration columnconfigured to be inserted within the first guide channel and the secondguide channel, respectively, so that the first registration column, thesecond registration column, the first guide channel and the second guidechannel are substantially disposed within the interior volume.

In one version of the embodiment, the plurality of registration elementsincludes a first registration key way and a second registration key wayconfigured to retain therewithin the first guide post and the secondguide post, respectively, so that the first registration key way, thesecond registration key way, the first guide post and the second guidepost are substantially disposed outside the interior volume.

In one embodiment, the lighting element includes a light emitting diode.

In one version of the embodiment, the back body includes a rear portioncoupled to the perimeter back body wall, the elongated chamber includingan ingress aperture formed in the rear portion, and wherein the lightingelement is removably disposed in the elongated chamber.

In one version of the embodiment, the lighting element is directlyterminated to a source of AC power.

In one embodiment, the switch actuator assembly includes a transmissionmechanism coupled to the actuator guide, the transmission mechanismbeing configured to convert the linear motion of the actuator guide intoa rotational movement when the switch actuator plate is depressed andthe actuator guide is driven toward the switch actuating position.

In one version of the embodiment, the transmission mechanism includes aplurality of gear teeth, the plurality of gear teeth being configured toapply a rotational movement to the mechanical switch mechanism inresponse to the linear motion of the actuator guide.

In one version of the embodiment, the device further comprises a switchactuator portion coupled between the transmission mechanism and at leasta portion of the mechanical switch assembly, the switch actuator portionbeing configured to move the mechanical switch assembly between thefirst switch state and the second switch state in response to therotational movement of the transmission mechanism.

In one embodiment, the device further comprises a housing having a frontportion and a back body portion, the housing being configured to beinstalled in an outlet box.

In one version of the embodiment, the mechanical switch mechanismincludes a set of electrical contacts switchably coupled to a pluralityof terminals at least partially disposed in the back body portion, theplurality of terminals being accessible via the back body portion.

In one version of the embodiment, the plurality of terminals including aline terminal, a load terminal or a traveler terminal.

In one version of the embodiment, the housing assembly further comprisesa separator member coupled between the back body member and the switchactuator assembly, the separator member providing a barrier between themechanical switch assembly and the interior volume.

In one version of the embodiment, the separator member includes at leastone ancillary registration element configured to mate with acorresponding structure disposed in the perimeter guide wall.

Additional features and advantages of the invention will be set forth inthe detailed description which follows, and in part will be readilyapparent to those skilled in the art from that description or recognizedby practicing the invention as described herein, including the detaileddescription which follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description are merely exemplary of theinvention, and are intended to provide an overview or framework forunderstanding the nature and character of the invention as it isclaimed. The accompanying drawings are included to provide a furtherunderstanding of the invention, and are incorporated in and constitute apart of this specification. The drawings illustrate various embodimentsof the invention and together with the description serve to explain theprinciples and operation of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B are perspective views of a frame member in accordance withthe present invention;

FIGS. 2A-2D are perspective views of a modular alignment connector inaccordance with the present invention;

FIGS. 3A-3B are isometric views of the push-switch in accordance withone embodiment of the present invention;

FIGS. 4A-4B are isometric view of the push switch depicted in FIG. 3Aprior to insertion into the frame depicted in FIGS. 1A-1B;

FIG. 5 is an exploded view of the push switch depicted in FIG. 3A;

FIGS. 6A-6B show a sectional view of the push switch depicted in FIG.3A;

FIGS. 7A-7C show alternate sectional views of the push switch depictedin FIG. 3A;

FIGS. 8A-8B show yet another sectional view of the push switch depictedin FIG. 3A;

FIGS. 9A-9E show various sectional views illustrating the operation ofthe push switch depicted in FIG. 3A; and

FIGS. 10A-10B show various views of the push-switch in accordance withanother embodiment of the present invention.

DETAILED DESCRIPTION

Reference will now be made in detail to the present exemplaryembodiments of the invention, examples of which are illustrated in theaccompanying drawings. Wherever possible, the same reference numberswill be used throughout the drawings to refer to the same or like parts.An exemplary embodiment of the push switch of the present invention isshown in FIG. 3, and is designated generally throughout by referencenumeral 100.

As embodied herein, and depicted in FIGS. 1A-1B, perspective views of aframe member 10 in accordance with the present invention are disclosed.FIG. 1A is directed to the rear side 10-2 of the frame member 10,whereas FIG. 1B is directed to the front side 10-1 of the frame member10. The frame member 10 is configured to “complete the electricalenclosure” when one or more modular electrical devices such as device100, and/or modular alignment connectors 20 are properly installedwithin the frame opening 10-13 such that the device wall box interior issubstantially inaccessible. Reference is made to U.S. patent applicationSer. No. 13/608,675, which is incorporated herein by reference as thoughfully set forth in its entirety, for a more detailed explanation ofother electrical wiring devices that may be used in combination withdevice 100 to render the wall box interior substantially inaccessible.Stated differently, instead of using a conventional wall plate tocomplete the enclosure, the frame member 10 together with the assemblageof wiring devices and/or modular alignment connectors preventsindividuals from being shocked or electrocuted by concealing allelectrical wiring under the frame 10 within the device wall boxinterior.

Thus, a frame enclosure lip 10-5 is disposed around the perimeter of theframe 10. The frame enclosure lip 10-5 is configured to substantiallyabut the wall surface 1 (not shown in this view) such that a front edgeof a properly installed wall box does not substantially touch the rearside 10-2 of the frame 10. This is true even when old work boxes aredeployed. Old work boxes, of course, have flanges that are mounted tothe outer surface of the wall surface 1. The frame enclosure lip 10-5raises the rear surface 10-2 overtop the work box to avoid anyinterference with the flanges and prevent the frame 10 from contactingthe wall surface 1.

As shown, the frame 10 includes a frame opening 10-13 that has aninterior serrated edge or lip 10-6 that is configured to mate with themodular alignment conductors 20 and/or the electrical wiring device 100in the manner disclosed below. Once electrical wiring device(s) and/orthe modular alignment connectors are installed within the frame opening10-13, the enclosure is completed. The interior serrated lip 10-6extends along lateral portions of the frame opening 10-13 to adjoin aconnector landing element 10-7 disposed at either end of the frameopening 10-13. The interior serrated lips 10-6 and the connector landingelements 10-7 extend perpendicularly around the entire frame opening10-12 to form a rim or skirt that is inserted inwardly within the devicebox interior during installation. Accordingly, the region under the rearframe surface 10-2 between the outer enclosure lip 10-5 and the interiorrim (i.e., serrated lips 10-6 and landing 10-7) is disposed over thewall surface 1. Once the wall box fasteners 10-10 are inserted into thefastener slots 10-12 and tightened, the interior of the device box isaccessed via the frame opening 10-13. After device installation,however, the frame opening 10-13 is completely occupied by somecombination of modular wiring devices (30, 40, 42 or 50) and/or modularalignment connectors 20 to thereby complete the enclosure. All of thewiring is under the frame assembly and cannot be accessed.

As embodied herein and depicted in FIGS. 2A-2D, perspective views of amodular alignment connector 20 in accordance with the present inventionare disclosed. The modular alignment connector 20 is said to be modularbecause it adjusts and aligns the size of the frame opening such thatvarious combinations of wiring devices (e.g., 30, 40, and 42) disposedin a variety of spatial orientations are used to complete the frameopening 10-13 when they are installed therein.

FIG. 2A shows a front major surface 20-1 of the modular alignmentconnector 20 (when it is inserted within the frame opening 10-13). Thefront major surface 20-1 of the modular alignment connector 20 has awidth of approximately 11.2 mm and a length of about 45 mm. One pair ofthe alignment connectors 20 are the same size as a one-module electricalwiring device. The front major surface 20-1 includes a front connectorflange 20-6 which is configured to fit within the frame connector seat10-14 when the connector is inserted within the frame 10. The modularalignment connector 20 also includes bending snap arms 20-3 and spacertangs 20-4 disposed on either side of the connector 20. A spacer channel20-5 is disposed between the snap arm 20-3 and the spacer tang 20-4. Astheir name suggests, the snap arms 20-3 are used to “snap” the alignmentconnector 20 into the frame opening 10-13. Subsequently, the spacer tang20-4 is pressed into the spacer channel 20-5 to lock the modularalignment connector 20 into the frame opening 10-13. The locked snaparms 20-3 retain the alignment connector 20 within the frame opening10-13 thereafter. Stated differently, when a spacer tang 20-4 isinserted into a channel 20-5, the snap arm 20-3 can no longer deflectinwardly and thus cannot be removed from place. The snap connectassembly (20-3, 20-4, and 20-5) is configured to withstand at least 50foot-pounds of pulling force.

Reference is made to U.S. patent application Ser. No. 13/608,675, whichis incorporated herein by reference as though fully set forth in itsentirety, for a more detailed explanation of the frame member 10.

FIG. 2B shows the modular alignment connector 20 rotated 180° withrespect to the view provided by FIG. 2A. The front stabilizing plate20-6 and the rear connector flanges 20-7 form a connector channel 20-8that is configured to grip the frame connector landing 10-7 (See FIGS.1A-1B). The front stabilizing plate 20-6 is seated on the frameconnector seat 10-14 when the alignment connector 20 is inserted intothe frame opening 10-13. The purpose of the front stabilizing plate 20-6is to help the connector 20 retain its position within the frame opening10-13 by preventing it from being pushed inwardly and through frameopening 10-13.

FIG. 2C is a rear view of the modular alignment connector 20. This viewshows a rear major surface 20-2 that is supported underneath by devicestop elements 20-9. Like the serrated stop elements 10-60 of theserrated lip 10-6, the device stop elements 20-9 are configured toengage and mate with the device snap elements formed in the modularwiring device housing (See elements 30-2, 40-2, etc., depicted in FIG.5) to complete the electrical enclosure. This snap-fit arrangement fixesthe modular wiring device (30-2, 40-2) within the opening 10-13 suchthat it cannot move laterally or longitudinally within the frame opening10-13 when snapped in place. Stated differently, the interior serratedlips 10-6 and device stop elements 20-9 serve to secure and align theelectrical wiring device (30, 40, 50, etc.) within the frame opening10-13.

FIG. 2D shows the modular connector 20 rotated 180° with respect to theview provided by FIG. 2C. When inserted into the frame opening 10-13,the rear stabilizing plate 20-7 bears against edges of the connectorlanding 10-7 (See FIGS. 1A-1B). Again, the front stabilizing plate 20-6and the rear stabilizing plate 20-7 form a channel 20-8 that restrictsthe movement of the modular alignment connector 20 after being seated onthe connector seat 10-14. As the connector 20 is moved to this seatedposition, bending snap arms 20-3 are deflected inwardly by the interiorserrated lip 10-6 until they clear and snap back outwardly into theserrations. Again, the bending snap arms 20-3 prevent the connector 20from sliding or moving out of its seated position.

Reference is made to U.S. patent application Ser. No. 13/608,675, whichis incorporated herein by reference as though fully set forth in itsentirety, for a more detailed explanation of the modular alignmentconnector 20.

As embodied herein and depicted in FIGS. 3A-3B, isometric views of thepush-switch 100 in accordance with one embodiment of the presentinvention are disclosed. FIG. 3A shows a front isometric view of thepush switch 100. Push switch 100 includes an actuator plate 102 thatincludes a lens structure 104 that is configured to allow light from alight source disposed in an internal portion of switch 100 to be emittedinto the ambient environment. Actuator plate 102 is substantially squareshaped and covers a major portion of the front surface of push switch100. FIG. 3B shows a rear isometric view of switch 100 and features theback body portion 108.

In reference to FIGS. 4A-4B, isometric views of the push switch 100 areshown prior to their insertion into the frame 10 depicted in FIGS. 1A-1Bare disclosed. Because push switch 100 is implemented herein in atwo-module form factor, a pair of modular alignment connectors 20 isdisposed at either end of the frame opening 10-13 to “complete theenclosure.” In FIG. 4A, the two-module push-switch 100 is disposedupright between the two connectors 20 to complete the enclosure. In FIG.4B, the two-module push-switch 100 is disposed sideways between the twoconnectors 20 to complete the enclosure. Push switch 100 may be orientedin any direction including upside down.

Referring to FIG. 5, an exploded view of the push switch 100 depicted inFIG. 3A is disclosed. The push switch 100 includes a switch actuatorplate 102 coupled to a slidable actuator guide 110. Slidable actuatorguide 110 includes a perimeter wall 110-4 that forms an enclosure. Theslidable actuator guide 110 is configured to accommodate light guide104-1 therein. The light guide includes two 45° mirrored sections thatare configured to direct the light emitted by an insertable lightingdevice (not shown in this view). The slidable actuator guide 110 alsoincludes two snap-in hinges that accommodate the trunions 114-1 formedat either end of the force transmission element 114. Note however, thatthe stabilizer element 112 prevents the force transmission element 114from rotating freely. The center portion 112-1 of the stabilizer 112snaps into the top middle portion of the force transmission element 114and the bearing elements 112-2 restrain the underside of the trunions114-1. Thus, the stabilizer element 112 provides stability to thetransmission element 114 such that transmission element's rotationalmovement is substantially limited to about +/−8° around the centerline.This feature allows the transmission element 114 to effectively transmitthe linear push force provided by the user via actuation plate 102 tothe rotatable actuator 116 without the gear teeth 114-2 becoming jammedor misaligned visa vis actuator 116.

The rotating actuator 116 is mounted on a center opening formed in theseparator member 106. As shown below, rotating actuator 116 includes aV-shaped portion or a notch that secures the switch pendulum 120 to therotatable actuator 116. A center spring element 118 is disposed betweenthe rotatable actuator 116 and the pendulum 120; the spring element 118provides a “snap-action” to the switch mechanism as it moves betweenswitch positions.

The separator 106 also includes four bosses 106-1 that are situated atthe four corners of the separator 106. In one embodiment, each boss106-1 accommodates a compression spring 106-2. The bosses 106-1 and thesprings 106-2 mate with guide openings 110-1 formed at the corners ofthe slidable actuator guide 110. Thus, when the user applies a pushforce to the actuator plate 102, the slidable actuator guide 110compresses the springs 106-2 as the bosses 106-1 move within the guideopenings 110-1 formed in slidable guide 110. Once the push force isremoved, the springs 106-2 release their stored energy and push theslidable guide 110 in the opposite direction to restore equilibrium. Inan alternate embodiment (shown in FIG. 7C), only two springs 106-2 arerequired. Obviously, in the two-spring embodiment, the spring force ofeach spring 106-2 must be increased relative to the four springembodiment.

Note also that the separator 106 includes stiffeners 106-4 formed in theupper side thereof to stabilize the shape of the separator. As explainedin greater detail below, the guide posts 110-3 and the channels 110-4also mate with registration elements (108-1, 108-2) formed in the backbody 108. Thus, the slidable actuator guide 110 is restrained from aboveand below to prevent an off-center push-force applied to actuator plate102 from jamming the switch. Stated differently, the combination of thesprings 106-2 (in either embodiment) and the multi-level registrationfeatures (i.e., 106-4, 106-5, 108-1, 108-2) ensure that the slidableguide member travels straight and true. In other words, the slidableguide member does not jam due to features incorporated in both theseparator and the back body. Moreover, because the slidable guide memberis constrained on either side by the separator and the back body, dustand other contaminants are substantially prevented from penetrating tothe interior of the back body 108 where the pendulum switch 120 resides.

In reference to FIGS. 6A-6B, a sectional view of the push switchdepicted in FIG. 3A is disclosed. In FIG. 6A, the sectional line B-B isthrough the line terminal 122 and traveler terminal 124 (not shown inFIG. 6A). In FIG. 6B, the switch actuator plate 102 is shown as beingcoupled to the slidable guide member 110. The light guide 104-1 isdisposed in an upper portion of the guide 110 and one end thereof iscoupled to the lens 104 formed in the switch actuator plate 102. Theslidable guide member 110 substantially encloses the interior of theswitch mechanism. As noted above, portions of the side walls of theslidable guide member 110 are disposed between the back body member 108and the registration columns 108-2, and the back body and separator suchthat dust and contaminants cannot penetrate to the interior of thedevice 100. The force transmission member 114 is flexibly held in asubstantially upright position such that gear teeth 114-1 aresubstantially disposed within the void formed in the interior ofrotatable actuator 116. As shown here, the rotatable actuator 116 isslightly rotated such that its centerline is substantially in the OneO'clock position. In this state, the pendulum is snapped into its switchposition by switch spring 118. In particular, the pendulum contact 120-1and traveler contact 126-2 are closed. Of course, the pendulum contact120-1 is electrically continuous with the line terminal 122 because itrotates within the cradle 122-1 portion of the line terminal 122.Pendulum switch 120 is further protected from dust contamination bywalls 108-6. In an embodiment of the invention, walls 108-6 form apocket in which pendulum switch 120 resides.

In reference to FIGS. 7A-7C, alternate sectional views of the pushswitch depicted in FIG. 3A are shown. These views are provided to againillustrate the contaminant prevention features of the present invention.FIG. 7A provides an upper sectional line E-E (FIG. 7B) and a lowersectional line C-C (FIG. 7C). In reference to FIG. 7B, the back body 108includes relatively wide registration columns 108-2 disposed in parallelwith the y-axis and relatively smaller registration posts 108-1 disposedin parallel with the x-axis. Registration posts 108-1 are accommodatedby the guide channels 110-3. The wide registration columns 108-2 areaccommodated by the guide channels 110-2 formed in the slidable guidemember 110. Moreover, the bosses 106-1 formed in the separator 106 areshown as being disposed within the guide openings 110-1 formed in theslidable guide member 110. Thus, the slidable guide member 110 slidablymoves within tightly defined channels formed by the back body 108 andthe separator to prevent contaminants from fouling the switch mechanism.Even if dust or other such contaminants were to find their way intothese extremely narrow channels, they would merely collect within thespace formed between the bottom of the guide 110 and the separator 106.The separator 106 (See FIG. 5) includes a domed or arched shape thataccommodates the switch mechanism, and thus acts like a dust cover ofcontaminant shield. Further, since the registration posts 108-1 andregistration columns 108-2 are disposed behind the guide walls 110-4(i.e., inside the channels 110-2, 110-3), the guide enclosure 110shields the guide channels (110-2, 110-3) from any dust or other suchcontaminants that might enter the device 100 via the small gap betweenthe guide 110 and the back body 108. Thus, the guide enclosure 110-4substantially prevents switch jamming or sticking due to accumulation ofcontaminants. Because the guide enclosure substantially inhibits dustand other contaminants, the clearances between the registration elements(108-1, 108-2) and the guide channels (110-2, 110-3) are relativelysmall. These tight tolerances substantially limit any skewing ofslidable guide member 110 (and hence prevent jamming) when the actuatorplate 102 is pushed by the user at an oblique angle (i.e., off-axis).Thus the push switch 100 of the present invention will not jam as aconsequence of being in a dusty environment or because of actuator plate102 being pushed at an oblique angle (off-axis).

In Reference to FIG. 7C, the compression springs 106-2 are shown asbeing disposed within the guide openings 110-1. The registration columns108-2 and posts 108-1, function as before: the slidable guide member 110is constrained both above and below, and also laterally, by the variouselements described above such that it slides linearly without thepossibility of being jammed by going askew.

In reference to FIGS. 8A-8B, yet another sectional view of the pushswitch depicted in FIG. 3A is disclosed. In this view, the arrangementof the insertable lighting mechanism relative to the switch mechanism isshown. FIG. 8A shows cross-sectional line D-D through the rear portionof back body member 108. In particular, the sectional line cuts throughlight tunnel opening 108-3. Moving from left to right in FIG. 8B, thesectional line cuts through the switch mechanism as previouslydescribed. The force transmission element 114 is disposed over therotatable actuator 116. Of course, the rotatable actuator 116 isconfigured to move the pendulum contact 120-1 between the travelercontacts (124-1, 126-1) in response to the application of a push forceto the switch actuation plate 102.

With respect to the sectional line D-D, note that is proceeds in astraight line from the left of the device until it reaches the centerpoint of the device 100; after this the sectional line D-D proceeds inan angular direction to expose the light tunnel 108-3. Briefly stated,the insertable light 30 is an optional feature. If the user desires touse it, it is inserted from the rear of the back body 108 into the lighttunnel 108-3 until the light emitter portion 30-3 abuts the stop portion106-3 formed in the separator member 106. When this occurs, the lightemitting head 30-3 is positioned within the slidable guide member 110proximate and adjacent to one end of the light pipe 104-1. This portionof the slidable guide member 110 includes a polished interior region110-30 that directs the emitted light into the light pipe 104-1. Asnoted previously, the light pipe 104-1 includes two 45° bends thatdirect the light toward lens 104 where it is emitted out into theambient environment. Due to these bends in the light pipe, lens 104,transmission element 114, and pendulum 120 are all in substantiallyalignment with the central axis of push switch 100. At the other end ofthe lighting device 30, hot and neutral pig-tails (2, 4) extendbackwardly from the light tunnel for connection to the line terminal 122and a traveler terminal (124 or 126), to traveler terminals (124,126),to an auxiliary power supply, or to line hot and neutral conductors,respectively.

In reference to FIGS. 9A-9E, various sectional views illustrating theoperation of the push switch 100 depicted in FIG. 3A are disclosed. InFIG. 9A, the force transmission element 114 is shown in a rest position(i.e., the user is not applying any force to plate 102). The pendulumcontact 120-1 and the traveler contact 126-1 are closed. Thetransmission element 114 includes two gear teeth 114-2, each of which isconfigured to transmit the user's applied linear actuation force to arespective actuation surface 116-2 disposed on either side of therotational axis 116-1. In FIG. 9B, the user applies a push force P1 (Seearrows) to the switch actuation plate 102 such that one of the gearteeth 114-2 makes contact with its respective actuation surface 116-2,whichever of the two surfaces is higher due to the rotational positionof pendulum 120 (one surface or the other is higher due to the switchstate established by the spring switch 118).

In FIG. 9C, as the amount of plate 102 displacement increases, the forcetransmission element 114 responds by beginning to rotate while slidingalong the actuation surface 116-2 in the direction R1. As shown in FIG.9D, when the gear tooth 114-2 engages the inner lip 116-4 of therotatable actuator 116, it causes the rotatable actuator to rotate inthe opposite direction R2. At the same time, the gear tooth 114-2 thatis not engaged slips into the central void 116-3 of the rotatableactuator 116. At some point in the sequence, the spring switch 118 snapsto cause the pendulum 120 to rotate in the direction R3 (opposite of R2)to change the switch state, and cause the pendulum contact 120-1 toengage the traveler contact 124-1. In FIG. 9E, the user is no longerapplying pressure to the actuation plate 102 and the spring forcesassociated with the springs 106-2 causes the slidable guide member 110to move away from the separator and back body to thus return to the reststate with contacts 120-1 and 124-1 being closed.

If plate 102 is then pushed again the process is repeated only this timethe actuation surface 116-2 on the left is higher and so is the one thatgets depressed by its respective gear tooth 114-2. Pendulum 120 rotatesin the opposite direction until it returns to the switch state shown inFIG. 9A under the snap action of switch spring 118.

Referring to FIGS. 10A-10B, various views of the push-switch inaccordance with another embodiment of the present invention aredisclosed. In FIG. 10A, the push switch 200 is configured in a standardwiring device form factor. The switch actuator 202 is implemented in arectangular design that conforms to the rectangular shape of the backbody 208. One difference between this embodiment and the previousembodiments relates to the mounting ears 203 coupled to the back body208. The mounting ears 203 typically include a ground terminalconfigured to secure a ground conductor thereto. The mounting ears areemployed, of course, to mount the device 200 directly to the device box300. Once the device 200 is mounted to the device box 300, the coverplate 201 is disposed overtop to complete the enclosure. FIG. 10B isfrontal view of the switch device 200 in combination with the coverplate 201. Once the cover plate 201 is attached, only the front cover202 and lens 204 (if provided) are visibly through the cover plate 201opening.

The components employed in FIGS. 10A and 10B are essentially the same asthose used in previous embodiments. Similar reference numbers are beingused to refer to the same or like parts with the exception that 200series numbers are employed in this embodiment instead of 100 seriesnumbers.

All references, including publications, patent applications, andpatents, cited herein are hereby incorporated by reference to the sameextent as if each reference were individually and specifically indicatedto be incorporated by reference and were set forth in its entiretyherein.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. The term “connected” is to beconstrued as partly or wholly contained within, attached to, or joinedtogether, even if there is something intervening.

The recitation of ranges of values herein are merely intended to serveas a shorthand method of referring individually to each separate valuefalling within the range, unless otherwise indicated herein, and eachseparate value is incorporated into the specification as if it wereindividually recited herein.

All methods described herein can be performed in any suitable orderunless otherwise indicated herein or otherwise clearly contradicted bycontext. The use of any and all examples, or exemplary language (e.g.,“such as”) provided herein, is intended merely to better illuminateembodiments of the invention and does not impose a limitation on thescope of the invention unless otherwise claimed.

No language in the specification should be construed as indicating anynon-claimed element as essential to the practice of the invention.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the present inventionwithout departing from the spirit and scope of the invention. There isno intention to limit the invention to the specific form or formsdisclosed, but on the contrary, the intention is to cover allmodifications, alternative constructions, and equivalents falling withinthe spirit and scope of the invention, as defined in the appendedclaims. Thus, it is intended that the present invention cover themodifications and variations of this invention provided they come withinthe scope of the appended claims and their equivalents.

What is claimed is:
 1. A switch device comprising: a device housingconfigured to be installed in an outlet box, the device housingincluding front portion and a back body portion; a switch assemblydisposed in the device housing, the switch assembly including a switchactuator having a user-accessible surface and coupled to the frontportion, the user accessible surface including an indicator elementdisposed therein, the switch actuator also including an interior channeloptically coupled to the indicator element, the switch assembly furtherincluding a mechanical linkage and a set of electrical contacts disposedwithin the back body portion, the switch actuator being configured toactuate the mechanical linkage by moving between a first actuatorposition and a second actuator position in response to a user-stimulus,the mechanical linkage actuation driving the set of electrical contactsbetween a first contact state and a second contact state; and a lightingassembly coupled to the back body portion at a fixed position so that alight emitting portion of the lighting assembly is disposed within theinterior channel and optically coupled to the indicator element, theinterior channel being configured to move relative to the light emittingportion when the switch actuator moves between the first actuatorposition and the second actuator position, the light emitting portionbeing optically coupled to the indicator element when the interiorchannel moves relative to the lighting portion.
 2. The device of claim1, The device of claim 1, wherein the lighting assembly is a modularcomponent removably coupled to the back body portion.
 3. The device ofclaim 1, wherein the back body portion includes an elongated chamberconfigured to accommodate the lighting assembly, the elongated chamberincluding a tapered portion configured to position the light emittingportion at the fixed position.
 4. The device of claim 1, wherein theswitch actuator includes a light transmitting element configured tooptically couple the interior channel to the indicator element.
 5. Thedevice of claim 4, wherein the light transmitting element is in a fixedpositional relationship with the interior channel.
 6. The device ofclaim 4, wherein the light transmitting element includes an LED element.7. The device of claim 1, wherein the switch actuator includes a lighttransmitting element having a first optical port and a second opticalport, the first port being coupled to the indicator element and thesecond port being coupled to the interior channel, and wherein the firstoptical port is substantially aligned with a central axis of the devicehousing and the second optical port is substantially offset from theaxis.
 8. The device of claim 6, wherein the light transmitting elementincludes a plurality of light transmitting segments disposed between thefirst port and the second ports.
 9. The device of claim 7, wherein theplurality of light transmitting segments includes at least one portionconfigured to direct incident light at a 45° angle.
 10. The device ofclaim 1, wherein the interior channel is polished.
 11. The device ofclaim 1, wherein the interior channel is plated with an opticallyreflective material.
 12. The device of claim 1, wherein the set ofelectrical contacts are switchably coupled to a plurality of terminalsat least partially disposed in the back body portion, the plurality ofterminals being accessible via the back body portion.
 13. The device ofclaim 11, wherein the plurality of terminals including a line terminal,a load terminal or a traveler terminal.
 14. The device of claim 1,wherein the indicator element is a lens element.
 15. The device of claim14, wherein the lens element is formed by machining a portion of theuser accessible surface.
 16. A switch device comprising: a switchactuator assembly including a switch actuation plate coupled to anactuator guide portion having a perimeter guide wall substantiallyenclosing an interior volume therewithin, the actuator guide portionbeing coupled to a force transmission member and further including aninterior channel, the switch actuation plate including a lens elementoptically coupled to a light transmission structure at least partiallydisposed in the interior channel; a back body member includes aperimeter back body wall, portions of the perimeter back body wall beingconfigured to mate with corresponding portions of the perimeter guidewall so that the perimeter guide wall is disposed within the perimeterback body wall in a nesting arrangement so that the interior volume issubstantially inaccessible to an exterior region of the device, the backbody member including an elongated chamber configured to position alighting element at a fixed position within the back body so that thelighting element extends into the interior channel, the actuator guidebeing configured to slide within the back body member in a substantiallylinear motion between a non-switch actuating position and a switchactuating position so that a relative distance between the lighttransmission structure and the lighting element varies within theinterior channel, the interior channel being configured so that lightintensity emitted by the lighting element via the lens element issubstantially constant while the relative distance varies; and a switchassembly configured to convert the linear motion of the actuator guideinto a rotational movement when the switch actuator plate is depressedso that the switch assembly moves between a first switch state and asecond switch state.
 17. The device of claim 16, wherein the interiorchannel is polished.
 18. The device of claim 16, wherein the interiorchannel is plated with an optically reflective material.
 19. The deviceof claim 16, wherein the light transmitting element includes a firstoptical port and a second optical port, the first port being coupled tothe lens element and the second port being coupled to the interiorchannel, and wherein the first optical port is substantially alignedwith a central axis of the device housing and the second optical port issubstantially offset from the axis.
 20. The device of claim 19, whereinthe light transmitting element includes a plurality of lighttransmitting segments disposed between the first port and the secondports.
 21. The device of claim 20, wherein the plurality of lighttransmitting segments includes at least one portion configured to directincident light at a 45° angle.
 22. The device of claim 16, wherein theactuator guide portion includes a plurality of guide portions formed inthe perimeter wall within the interior volume, the perimeter back bodywall having a plurality of registration elements, each of the pluralityof registration elements being insertably disposed within acorresponding one of the plurality of guide portions.
 23. The device ofclaim 22, wherein the plurality of registration elements are configuredto substantially prevent rotational movement of the actuator guidewithin the back body member about an axis of the switch device normal tothe direction of linear movement.
 24. The device of claim 22, whereinthe plurality of registration elements are configured to substantiallyprevent rotational movement of the actuator guide within the back bodymember about the central axis.
 25. The device of claim 22, wherein theguide elements includes a first guide channel and a second guide channelformed on a first perimeter guide wall and a second perimeter guidewall, respectively, and a first guide post and a second guide postformed on a third perimeter guide wall and a fourth perimeter guidewall, respectively.
 26. The device of claim 25, wherein the plurality ofregistration elements includes a first registration column and a secondregistration column configured to be inserted within the first guidechannel and the second guide channel, respectively, so that the firstregistration column, the second registration column, the first guidechannel and the second guide channel are substantially disposed withinthe interior volume.
 27. The device of claim 26, wherein the pluralityof registration elements includes a first registration key way and asecond registration key way configured to retain therewithin the firstguide post and the second guide post, respectively, so that the firstregistration key way, the second registration key way, the first guidepost and the second guide post are substantially disposed outside theinterior volume.
 28. The device of claim 16, wherein the lightingelement includes a light emitting diode.
 29. The device of claim 28,wherein the back body includes a rear portion coupled to the perimeterback body wall, the elongated chamber including an ingress apertureformed in the rear portion, and wherein the lighting element isremovably disposed in the elongated chamber.
 30. The device of claim 29,wherein the lighting element is directly terminated to a source of ACpower.
 31. The device of claim 16, wherein the switch actuator assemblyincludes a transmission mechanism coupled to the actuator guide, thetransmission mechanism being configured to convert the linear motion ofthe actuator guide into a rotational movement when the switch actuatorplate is depressed and the actuator guide is driven toward the switchactuating position.
 32. The device of claim 31, wherein the transmissionmechanism includes a plurality of gear teeth, the plurality of gearteeth being configured to apply a rotational movement to the mechanicalswitch mechanism in response to the linear motion of the actuator guide.33. The device of claim 31, further comprising a switch actuator portioncoupled between the transmission mechanism and at least a portion of themechanical switch assembly, the switch actuator portion being configuredto move the mechanical switch assembly between the first switch stateand the second switch state in response to the rotational movement ofthe transmission mechanism.
 34. The device of claim 16, furthercomprising a housing having a front portion and a back body portion, thehousing being configured to be installed in an outlet box.
 35. Thedevice of claim 34, wherein the mechanical switch mechanism includes aset of electrical contacts switchably coupled to a plurality ofterminals at least partially disposed in the back body portion, theplurality of terminals being accessible via the back body portion. 36.The device of claim 35, wherein the plurality of terminals including aline terminal, a load terminal or a traveler terminal.
 37. The device ofclaim 34, wherein the housing assembly further comprises a separatormember coupled between the back body member and the switch actuatorassembly, the separator member providing a barrier between themechanical switch assembly and the interior volume.
 38. The device ofclaim 37, wherein the separator member includes at least one ancillaryregistration element configured to mate with a corresponding structuredisposed in the perimeter guide wall.